Security feature based on a single axis alignment of mirrors in a structured surface that forms a micro mirror array

ABSTRACT

The disclosure relates to an optical security feature that is based on a single axis alignment of mirrors or facets in a structured surface that forms a micro mirror array. In an aspect, a device is described that includes a reflecting structure on a first layer, where the reflecting structure has a top surface with multiple embossed facets arranged in a spatial orientation that produces a flat ring optical effect upon incidence of light. In another aspect, a method for making the device is described that provides a reflecting layer and produces the reflecting structure on the reflecting layer with multiple facets arranged in the spatial orientation to produce the flat ring optical effect. In yet another aspect, an apparatus for making the device is described that includes a pressing device and a stamping device to transfer a pattern of the reflecting structure to a reflecting material.

RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/981,566, filed May 16, 2018 (now U.S. Pat. No. 10,618,340), which isincorporated herein by reference.

BACKGROUND OF THE DISCLOSURE

Aspects of the present disclosure generally relate to a security featurethat is based on a single axis alignment of mirrors in a structuredsurface that forms a micro mirror array, and more particularly, to theuse of foil or other embossed or stamped devices to generate thesecurity feature.

Optical effects such as depth, motion, and morphing have been used togenerate security features for various applications, including banknotes and other types of valuable documents. Security features generallyinvolve three different lines of defense against counterfeiting. A firstline of defense includes overt security features such as watermarks,intaglio printing security threads, holograms, optically variable inks,and other features detectable by the naked eye. A second line of defenseincludes covert features such as magnetic inks, bar codes, luminescentprinting, and retroflection. A third line of defense contains featuresdetectable by forensic experts using laboratory equipment. The featuresin the first line of defense can be generally divided into opticallyinvariable features and optically variable features or OVDs, the latterof which involves features displaying themselves in reply to an externalstimulus applied to the bank note or the document by the observer.

One approach to generate or produce devices or articles with opticallyvariable features is to form an array of magnetically-orientableplatelets or flakes having reflective surfaces and aligned as concave orconvex reflectors in a vehicle layer (e.g., dispersed in a fluidcarrier) by the application of a magnetic field in a predefined spatialorientation. Once aligned and set (e.g., through ultra-violet (UV)curing), the array of flakes can produce different types of opticalsecurity features (e.g., optical effects).

A different approach to generate or produce devices or articles withoptically variable features is to form on a foil or similar material astructured surface with an array of embossed segments or facets havingreflective surfaces. The reflective facets may be referred to as micromirrors and the overall array as a micro mirror array. The predefinedalignment and orientation of the facets in the array can producedifferent types of optical security features as well.

In many scenarios, a Fresnel equivalent-shaped reflective structure madeusing the embossed foil approach can produce the same or similar opticaleffect to a counterpart reflective structure made of magneticallyaligned flakes. There are scenarios, however, in which the opticaleffects or features produced by magnetically aligned flakes may not beeasily reproduced by the embossed or stamped foil approach, limiting theability of those that have implemented the embossed foil approach intotheir first line of defense from introducing more advanced and secureoptical features that may be implemented using magnetically alignedflakes.

Accordingly, mechanisms or techniques are desirable that allow for someoptical effects to be implemented as optically variable securityfeatures when using the embossed or stamped foil approach.

SUMMARY OF THE DISCLOSURE

The following presents a simplified summary of one or more aspects inorder to provide a basic understanding of such aspects. This summary isnot an extensive overview of all contemplated aspects, and is intendedto neither identify key or critical elements of all aspects nordelineate the scope of any or all aspects. Its purpose is to presentsome concepts of one or more aspects in a simplified form as a preludeto the more detailed description that is presented later.

Mechanisms or techniques are generally described that enable a securityfeature (e.g., flat ring feature or flat ring optical effect) that isbased on a single axis alignment of mirrors in a structured surface thatforms a micro mirror array. The micro mirror array may be formed byembossing or stamping a foil to produce multiple reflecting facets(e.g., micro mirrors) on the surface of the foil. The facets arearranged in a certain spatial orientation to generate the securityfeature. The spatial orientation may be such that each facet is alignedor ordered along a first axis and is randomly (e.g., pseudo-random)positioned relative to a second axis perpendicular to the first axis.While this single axis alignment may occur naturally in arrays ofmagnetically aligned flakes, such single axis alignment, and the randomalignment, orientation, or ordering that needs to occur in the otheraxis, have to be explicitly implemented as part of the design of thestructured surface of the embossed foil.

In an aspect of the disclosure, an example of an optically variabledevice is described that includes a first layer; and a reflectingstructure disposed on the first layer, where the reflecting structurehas a top surface including multiple embossed facets, and where thefacets are arranged in a spatial orientation that produces a flat ringfeature or optical effect upon incidence of light.

In another aspect of the disclosure, an example of a method for makingan optically variable device is described that includes providing areflecting layer; and producing a reflecting structure on the reflectinglayer having multiple facets, the facets being arranged in a spatialorientation that produces a flat ring feature or optical effect uponincidence of light.

In yet another aspect of the disclosure, an example of an apparatus formaking an optically variable device is described that includes apressing device, and a stamping device coupled to the pressing deviceand configured to transfer a pattern to a reflecting material upon theexertion of pressure by the pressing device, where the pattern includesa reflecting structure having multiple facets arranged in a spatialorientation that produces a flat ring feature or optical effect uponincidence of light on the patterned reflective material.

BRIEF DESCRIPTION OF THE DRAWINGS

The appended drawings illustrate only some implementation and aretherefore not to be considered limiting of scope.

FIG. 1 is a schematic diagram that shows an example of an apparatus fororienting magnetic flakes to generate a structure that produces anoptical effect in accordance with aspects of this disclosure.

FIG. 2A is a diagram that shows a funnel-shaped magnet for orientingmagnetically-orientable flakes to produce a flat ring optical effect inaccordance with aspects of the disclosure.

FIG. 2B is a diagram that shows an example of a cross-sectional view ofa funnel-shaped magnet in accordance with aspects of the disclosure.

FIG. 3A is a diagram that shows an example of a magnetic fieldconfiguration produced by a funnel-shaped magnet in accordance withaspects of the disclosure.

FIG. 3B is a diagram that shows a single-axis alignment ofmagnetically-orientable flakes under the field of a funnel-shaped magnetin accordance with aspects of the disclosure.

FIG. 4A is a diagram that shows an example of a flat ring optical effectfrom illumination by a single-point light source produced bymagnetically-orientable flakes aligned using a funnel-shaped magnet inaccordance with aspects of the disclosure.

FIG. 4B is a diagram that shows an example of movement of a flat ringoptical effect by tilting in accordance with aspects of the disclosure.

FIG. 4C is a diagram that shows an example of multiple flat ring opticaleffects from illumination by different light sources from differentdirections in accordance with aspects of the disclosure.

FIG. 5 is a diagram that shows an example of the optical effect producedby an embossed foil without randomness in an axis of facets in astructured surface in accordance with aspects of the disclosure.

FIG. 6A is a diagram that shows an example of an optically variabledevice made of an embossed foil with multiple facets that produces aflat ring optical effect in accordance with aspects of the disclosure.

FIGS. 6B and 6C are diagrams that show an example of alignment of facetsin an optically variable device along an axis in a radial direction withrandomness along a perpendicular axis to produce the flat ring opticaleffect in accordance with aspects of the disclosure.

FIGS. 6D and 6E are diagrams that show an example of randomness offacets in an optically variable device along an axis in an angulardirection with alignment along a perpendicular axis to produce the flatring optical effect in accordance with aspects of the disclosure.

FIG. 7 is a flow diagram that shows an example of a method for making anoptically variable device in accordance with aspects of this disclosure.

FIG. 8A is a schematic diagram that shows an example of an apparatus formaking an optically variable device in accordance with aspects of thisdisclosure.

FIG. 8B is a diagram that shows an example of a cast or stamp used totransfer a pattern to make an optically variable device in accordancewith aspects of this disclosure.

FIG. 9 is a flow diagram that shows an example of another method formaking an optically variable device in accordance with aspects of thisdisclosure.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appendeddrawings is intended as a description of various configurations orimplementations, and is not intended to represent the onlyconfigurations or implementations in which the concepts described hereinmay be practiced. The detailed description includes specific details oraspects for the purpose of providing a thorough understanding of variousconcepts. However, it will be apparent to those skilled in the art thatthese concepts may be practiced without these specific details.

As used in this disclosure, the terms “a” and “an” are intended todenote at least one of a particular element, the terms “include” and“including” are intended to mean includes and including, respectively,but not limited to, and the term “based on” is intended to mean based atleast in part on. Also as used in this disclosure, the terms“substantially,” “approximately,” and about indicate a range of valueswithin and including ±5% of the stated value (e.g., ±1%, ±2%, ±3%, ±4%,±5%).

As described above, the disclosure provides mechanisms or techniquesthat enable a security feature (e.g., flat ring feature or flat ringoptical effect) that is based on a single axis alignment of mirrors in astructured surface that forms a micro mirror array. The micro mirrorarray may be formed by embossing or stamping a foil to produce multiplereflecting facets (e.g., multiple small or micro mirrors) on the surfaceof the foil. The facets are arranged in a certain spatial orientation togenerate the security feature. The spatial orientation may be such thateach facet is aligned or ordered along a first axis and is randomly(e.g., pseudo-randomly) positioned relative to a second axisperpendicular to the first axis. While this single axis alignment mayoccur naturally in arrays of magnetically aligned flakes, such single(i.e., first) axis alignment, and the random alignment, orientation, orordering that needs to occur in the second axis, have to be explicitlyimplemented as part of the design of the structured surface of theembossed foil. That is, in the design or implementation of thestructured surface, a certain amount of tilting or rotating about thesecond axis has to be introduced for each of the facets, where theamount of tilting or rotating for each facet is randomly orpseudo-randomly selected. As such, the amount of tilting or rotatingthat is introduced can result in a series of adjacent facets havingdifferent rotations about the second axis, where some are rotatedclockwise, some counterclockwise, some rotated by a large angle, andsome rotated by a small amount or not rotated at all.

It is to be understood that the components, parts, or systems shown inFIGS. 1-6E, 8A, and 8B to describe various aspects of the articles,devices, apparatuses, and/or mechanisms proposed in this disclosure arenot intended to be drawn to scale and, in some instances, may instead bedrawn in such a way as to exaggerate certain physical characteristics orattributes for illustrative purposes.

FIG. 1 shows an apparatus 100 for orienting magnetically-orientableflakes. The apparatus 100 may include a magnet 102. The magnet 102 maybe, for example, a funnel-shaped magnet as described below in connectionwith FIG. 2A that affects an alignment/orientation of the flakes toproduce a flat ring feature or optical effect when the flakes areilluminated. The magnet 102 may have opposite poles to apply a magneticfield having magnetic field lines emanating from the magnet 102.Magnetic vector forces, which may also be termed “magnetic induction,”may be defined as forces that may be applied by the magnetic field invarious directions that emanate from the magnet 102.

The apparatus 100 is also shown to include a feeding mechanism 110 inthe form of a pair of rollers arranged to feed a substrate 116 in a feeddirection 114. Although the substrate 116 has been depicted as beingdirectly fed by the rollers, the substrate 116 may instead be supportedon a support (not shown). Other kinds of feeding mechanisms arepossible. The support, if employed, may be a belt, a platform, one ormore rows of grippers, a frame, or the like, and may support thesubstrate 116 such that the substrate 116 may be moved in the feeddirection 114 along with the support as the rollers of the feedingmechanism 110 are rotated. The apparatus 100 may include additionalfeeding mechanisms (not shown) provided upstream and/or downstream ofthe feeding mechanism 110.

The substrate 116 may be formed of paper, plastic film, laminate, cardstock, or the like. In a particular example, the substrate 116 may be abank note or other important document (or may be a film or layer that issubsequently attached to a bank note or other important document). Inaddition, at least a portion of an upper surface of the substrate 116may be coated with a fluid carrier 118 in which magnetically-orientableparticles or flakes are dispersed. The substrate 116 may be referred toas a first or bottom layer and the fluid carrier 118 may be referred toas a second, top, or vehicle layer. The fluid carrier 118 may also betermed an ink, a wet ink, a coating, a fluid coating, or the like. Thefluid carrier 118 may be applied through a printing technique such asgravure, ink-jet printing, flexographic, Intaglio, silk screen printing,painting, etc. The fluid carrier 118 may be in the form of ink or paintand may remain in a fluid form for at least a predetermined length oftime or until a sufficient amount of energy is applied onto the fluidcarrier 118. For instance, the fluid carrier 118 may be a liquid or apaste-like carrier and may be curable (e.g., may be set) through receiptof energy in the form of ultra-violet (UV) light, electron beam, heat,laser, etc. By way of particular example, the fluid carrier 118 may be aphotopolymer, a solvent-based carrier, a water-based carrier, or thelike. In addition, the fluid carrier 118 may be transparent, eitherclear, colorless, or tinted.

In one example, the fluid carrier 118 with the magnetically-orientableflakes may be applied onto the substrate 116 immediately prior to thesubstrate 116 being fed over the magnet 102 such that the fluid carrier118 remains in a fluid state as is moved over the magnet 102. Themagnetically-orientable flakes may be mixed into the fluid carrier 118prior to or after the fluid carrier 118 has been applied onto thesubstrate 116. The magnetically-orientable flakes are non-spherical andplanar flakes, that is, pigment flakes that can be aligned using amagnetic field, and may be reflective and/or may be color shifting(e.g., a flake may appear to have one color at one observation angle andanother color at another observation angle). The magnetically-orientableflakes may or may not retain remnant magnetization. By way of example, atypical magnetically-orientable flake may be anywhere from about 1 toabout 500 micrometers across and anywhere from about 0.1 to about 100micrometers thick. In addition, the magnetically-orientable flakes mayinclude a metallic layer, such as a thin film of aluminum, gold, nickel,platinum, metal alloy, etc., or may be a metal flake, such as a nickel,iron, or alloy flake. Alternatively, the magnetically-orientable flakesmay be coated with a tinted layer, or may include an opticalinterference structure, such as an absorber-spacer-reflector Fabry-Perottype structure.

According to an example, the substrate 116 may be moved through themagnetic field of the magnet 102 before the fluid carrier 118 sets ordries to enable the magnetically-orientable flakes to become oriented inthe direction of the magnetic field (e.g., vector forces). In addition,as the vector forces are not uniform across the magnet 102, theorientations of the magnetically-orientable flakes may vary dependingupon the locations of the magnetically-orientable flakes with respect tothe poles of the magnet 102. As such, the orientations of themagnetically-orientable flakes may change as the substrate 116 is fedthrough the magnetic field applied by the magnet 102.

The apparatus 100 may also include a radiation source 120 (or an arrayof radiation sources 120), which may apply radiation onto the fluidcarrier 118 to cure or otherwise solidify the fluid carrier 118 as thesubstrate 116 is fed in the feed direction 114. The radiation source 120may apply radiation in the form of ultra-violet (UV) light, electronbeam, heat, laser, or the like. A mask 122 having at least one opening124 is also shown as being positioned between the radiation source 120and the fluid carrier 118 to control which portion or portions of thefluid carrier 118 receives radiation from the radiation source 120 asthe substrate 116 passes by the radiation source 120. The at least oneopening 124 is strategically positioned with respect to the magnet 102and radiation source 126 to cause the magnetically-orientable flakes tobe at least partially fixed at predetermined orientations whilepreventing other magnetically-orientable flakes from being at leastpartially fixed at other orientations.

In some examples, a second radiation source 126 may also be used toapply energy onto the fluid carrier 118 in the form of UV light,electron beam, heat, or the like. The second radiation source 126 mayapply the same type of energy or a different type of energy as comparedwith the radiation source 120. The second radiation source 126 may beoptional and may be implemented to further solidify the fluid carrier118 and thereby set the magnetically-orientable flakes in a fixedposition or configuration that provides the desired optical effect whenlight is incident upon the oriented flakes.

One of the optically variable features that can be produced bymagnetically orienting flakes using the apparatus 100 in FIG. 1 is aflat ring feature or optical effect (see e.g., FIG. 4A). In order toachieve a flat ring from a single-point light source, the flakes need tobe arranged in a specific manner and a particular type of magnet may beneeded to create the appropriate magnetic field (e.g., vector forces)profile or configuration such that the flakes align in a desired spatialorientation. FIG. 2A shows a diagram 200 having a funnel-shaped magnet210 for orienting magnetically-orientable flakes to produce a flat ringoptical effect. The funnel-shaped magnet 210 may correspond to themagnet 102 described above in connection with the apparatus 100 inFIG. 1. The funnel-shaped magnet 210 may be made of, for example, acompression bended neodymium boron material and may be constructed byhaving a disk-shaped magnet machined to produce the funnel shape. In anexample, the angle of the funnel inside the magnet may vary fromapproximately 30° to approximately 90° (e.g., approximately 30°, 35°,40°, 45°, 50°, 60°, or 75°). A diagram 220 is shown in FIG. 2B toillustrate a cross-sectional view 230 of the funnel-shaped magnet 210 inwhich the angle of the funnel inside the magnet can be more clearlyseen.

In some implementations, a thin sheet metal (not shown) made fromMu-metal (e.g., nickel-iron soft ferromagnetic alloy) having a centralopening may be placed over the funnel-shaped magnet 210 to bend itsfields around its edges and slightly modify the magnetic fieldconfiguration (e.g., magnetic field lines or direction of vectorforces).

Other types of magnets may also be used instead of the funnel-shapedmagnet 210. For example, two concentric magnets (with one inside theother) may also be used to orient magnetically-orientable flakes toproduce a similar optical effect as the funnel-shaped magnet 210.Moreover, variations of the funnel-shaped magnet 210 may be used,including magnets with square, pentagonal, hexagonal, elliptical, andtriangular funnels. The optical effects produced from using thesevariations of the funnel-shaped magnet 210 may also be referred to flatring features or flat ring optical effects, even though the actualeffect may not be circular in nature.

In an example, the funnel-shaped magnet 210 may have its poles at thetop (negative pole—N) and bottom (positive pole—P) as illustrated in thediagram 220 in FIG. 2B. Other pole configurations may also be possibleto use and need not be limited to the example shown in the diagram 220.

FIG. 3A illustrates a diagram 300 that shows an example of a magneticfield configuration produced by a funnel-shaped magnet such as thefunnel-shaped magnet 210 in FIG. 2A (although the cross-sectional view230 is shown in FIG. 3A). The magnetic field can be depicted as havinglines of magnetic field 315 (flux density) emanating from the poles ofthe magnet. In the diagram 300, the lines of magnetic field 315 aremerely illustrative and are not intended to provide an accurate andcomplete picture of the entire magnetic field produced by thefunnel-shaped magnet 210. In an aspect, the lines of magnetic field 315may vary depending on the angle of the funnel inside the funnel-shapedmagnet 210.

In general, when orienting magnetically-orientable flakes using themagnetic field produced by a magnet, the flakes tend to align themselvesalong the lines of magnetic field 315. FIG. 3B illustrates a diagram 320that shows a single-axis alignment of magnetically-orientable flakesunder the magnetic field of a magnet such as the funnel-shaped magnet210 in FIG. 2A. As used within this disclosure, the terms“magnetically-orientable flakes,” “flakes,” and “platelets” may be usedinterchangeably to refer to reflective flakes before or after beingoriented. The diagram 320 includes a first flake 325 a and a secondflake 325 b. Although only two flakes are being shown in this example,it is understood that the concepts being illustrated by the flakes inthe diagram 320 apply more generally to a larger group of flakes beingoriented using a magnet. It is also to be understood that for any array,group, or arrangement of a large number of flakes, the flakes are likelyto be uniform in both shape and size, although there may be instances inwhich flakes of different sizes and/or different shapes are used.

In the example in the diagram 320, the flakes 325 a and 325 b areassumed to generally have a shape or form with two main axes. The flake325 a aligns or orients itself with a longest or first axis along thedirection of a line of magnetic field 315. Similarly, the flake 325 baligns or orients itself with a longest or first axis along thedirection of a line of magnetic field 315. For the flake 325 a, a secondor shortest axis 330 a, perpendicular to the longest axis, is alsoshown. Similarly, for the flake 325 b, a second or shortest axis 330 b,perpendicular to the longest axis, is also shown. While the flakes 325 aand 325 b are aligned, oriented, or ordered in the direction of the lineof magnetic field 325, that is not the case perpendicularly to the lineof magnetic field 315.

For the flake 325 a, the second axis 330 a may pivot, tilt, or rotatefreely (until the flake is set by curing) and, therefore, there may bean angle α₁ (0≤α₁≤360°, or α₁≤±90°) between the second axis 330 a and asurface perpendicular to the line of magnetic field 315 (represented byline 335 a) such that there is a degree of freedom in the orientation ofthe flake 325 a in this direction.

Similarly, for the flake 325 b, the second axis 330 b may pivot, tilt,or rotate freely (until the flake is set by curing) and, therefore,there may be an angle α₂ (0≤α₂≤360°, or α₂≤±90°) between the second axis330 b and a surface perpendicular to the line of magnetic field 315(represented by line 335 b) such that there is a degree of freedom inthe orientation of the flake 325 b in this direction.

Therefore, the flakes 325 a and 325 b experience a single-axis alignmentalong the first or longest axis and in the direction of the line ofmagnetic field 315. There is no such order or alignment along the secondaxis. Moreover, the amount of the rotation in the second axis isgenerally random and may occur naturally as part of the magneticorientation process performed by the apparatus 100 given that the flakes325 a and 325 b are dispersed in a fluid medium before such medium ishardened.

It is this alignment on a first axis and random rotation on a secondaxis for each flake (e.g., single-axis alignment), in combination withthe magnetic field produced by the funnel-shaped magnet 210, that allowsfor an array of flakes oriented in this manner to produce the flat ringoptical effect when illuminated by a light source.

FIG. 4A shows a diagram 400 with an example of a flat ring opticaleffect in the form of a circle 420 resulting from illumination by alight source 430. The optical effect is produced bymagnetically-oriented flakes aligned using a funnel-shaped magnet suchas the funnel-shaped magnet 210 in FIG. 2A. In the diagram 400, asubstrate (card or base layer) 410 may include a printed or reflectivelayer 415. The substrate 410 may correspond to the substrate 116 in FIG.1 and the printed layer 415 may correspond to the fluid carrier 118 inFIG. 1 after it has been cured or hardened to set the orientation of theflakes within it.

The substrate 410 may be tilted such that the upper portion moves awayfrom an observer, as illustrated in a diagram 450 in FIG. 4B. As seen inthe diagram 450, the lower portion of the printed layer 415 is nowlighter and the circle 420 moves in the direction of the bottom of theprint layer 415, exhibiting different distances between the circle 420and the upper and lower portions of the printed layer 415. The lighterarea of the printed layer 415 reflects light differently because theflakes in these areas, having the same alignment in radial regions, arealigned at different angles with respect to the observer. As a result,the printed layer 415 obtains a gradient from dark in the upper portionto light in the lower portion. The contrast difference and the shadowingdepicted in FIG. 4B creates the perception of volume and depth becausethe human visual system considers brighter objects to be closer to anobserver than darker objects. As such, the volume combined with theillusive motion of the circle 420 give the perception of flotation, thatis, it appears as if the circle 420 is floating beneath a surface of theprint layer 415 and above a background with gradient of color and depth.

When the substrate 410 with the print layer 415 remains tilted as inFIG. 4B but it is also illuminated with an additional light source 470located at some distance from the light source 430 as illustrated inFIG. 4C, it creates the appearance of an additional circle 422 at somedistance from the circle 420 in the direction of the light source 470.Both the circle 420 and the circle 422 may have the same color andintensity of a reflected light if the color of the flakes (e.g., apigment of the flakes) in the print layer 415 is silver-like or all theflakes are colored in a single color. That is, if the two light sources430 and 470 are of a same color so will be the circles 420 and 422,otherwise the circles 420 and 422 will be of different colors. Thecircle 420 and the circle 422 can have different colors if magneticcolor-shifting interference pigments were used for the flakes in theprint layer 415.

Thus, FIGS. 4A-4C describe some of the aspects associated with the flatring optical effects that can be produced when natural alignment on afirst axis and random rotation on a second axis for each flake (e.g.,single-axis alignment as illustrated in FIG. 3B) occurs in combinationwith the magnetic field produced by the funnel-shaped magnet 210.

That is, magnetically-oriented flakes have a specific way of aligning instatic magnetic fields that results in unique optical effects such asthe flat ring optical effect. These optical effects, however, cannot beachieved with smooth surface reflector shapes (e.g., structured surfacewith an array of embossed segments or facets having reflectivesurfaces). In other words, when a foil, substrate, or layer having astructured surface with a micro mirror array is used instead ofmagnetically-oriented flakes, these same optical effects would not bevisible under light illumination because reflections from a smoothsurfaces such as the surfaces of the aligned mirrors in the micro mirrorarray are specular in all directions.

For example, when a foil, substrate, or layer has a micro mirror array(e.g., an array or arrangement of small mirror or facets) that is usedto emulate the outside surface of a sphere, the mirrors are aligned in aplane parallel to the sphere surface. Such a reflector would not producethe same optical effects as described above in connection with FIGS.4A-4C. Instead, as illustrated in a diagram 500 in FIG. 5, such areflector would produce dots or spots 520 a and 520 b to an observer540, but not a flat-circle 510, when illuminated by light source 530. Inother words, an undesirable optical effect would occur instead of thedesirable flat ring optical effect.

To address this problem and provide a solution that enables yet anotherway to produce the unique optical effects described in this disclosure,techniques are described to control the direction, orientation, orrotation of each individual mirror in a micro mirror array to emulate oreven surpass the optical effects that can be achieved usingmagnetically-oriented flakes. As such, when using a micro mirror arrayto emulate the outside surface of a half sphere as described above, byaligning the mirrors or facets in a micro mirror array on an axisparallel to the sphere surface on radial lines and having a distributedor random (e.g., pseudo-random) alignment perpendicular to the radiallines, then the optical effects described herein may be possible usingan embossed foil with a surface structure having the micro mirror array.This is possible at least in part because the reflection pattern fromthe latter alignment can emulate the reflection from a sphere with a“brushed” surface, which is vastly different than the reflection from asphere with a “smooth” surface. The reflection from the “smooth” surfaceis specular in all directions, however, the reflection from the brushedsurface is specular in some directions and diffuse in others.

FIG. 6A shows an example of an optically variable device 600 that iscapable of producing a flat ring optical effect as described above inconnection with FIGS. 4A-4C. The optically variable device 600, whichmay be referred to as an optical device, a device, an article, or areflector, may include a substrate or layer 610 and a reflectingstructure 615. The reflecting structure 615 may be embossed or stampedto produce an array or arrangement of micro mirrors. As used in thisdisclosure, the terms “micro mirrors,” “facets” and “segments” may beused interchangeably to refer to small, angled, and reflecting surfacestructures that collectively emulate a reflector shape and that can beproduced by various techniques including embossing and stamping, forexample.

FIG. 6A shows both a top view of the optically variable device 600 and aside view of the same device. The relative sizes and thicknesses of thesubstrate 610 and the reflecting structure 615 are provided by way ofillustration and need not be considered limiting.

Also shown in FIG. 6A is a radial direction or line 625 from a center ofthe reflecting structure 615 and a portion 620 of the reflectingstructure 615 along the radial direction 625. An expanded view of theportion 620 is shown illustrating a small part of a micro mirror arrayon the reflecting structure 615. Within the portion 620 there aremultiple facets 630 arranged into rows and columns, for example(although other arrangements may also be used). It is to be understoodthat the shape and size of the facets 630 are assumed to be generallyuniform throughout the reflecting structure 615. However, there may beimplementations in which the shape, size, and/or arrangement of thefacets 630 may change based on, for example, the location of a facet inthe reflecting structure 615.

With respect to the portion 620, a view along A-A′ parallel to theradial direction 625 is illustrated in a diagram 640 in FIG. 6B. In thisexample, seven (7) facets 630 are shown for purposes of illustration.The facets 630 are formed, constructed, or otherwise shaped on a topsurface of the reflecting structure 615. The reflecting structure 615may itself be part of a reflecting layer. That is, the reflectingstructure 615 may simply be a reflecting layer on which the facets 630have been formed. In one implementation, the reflecting structure 615may be disposed on another layer 645 (optional layer), which may be madeof the same or different material as the reflecting structure 615.Moreover, the layer 645 may be part of, or may be disposed or positionedon, the substrate 610, where the substrate 610 can be a bank note oranother valuable document, for example.

Returning to FIG. 6B, each of the facets 630 in the diagram 640 isconfigured or formed to have a specified angle relative to a plane ordirection perpendicular to the surface of the reflecting structure 615as shown by angles β₁, β₂, β₃, β₃, β₄, β₅, β₆, and β₇, which may be thesame or different depending on the implementation of the reflectingstructure 615.

A perspective view of some of the facets 630 in the diagram 640 is shownin a diagram 650 in FIG. 6C. In this view, each of the facets 630 a, 630b, and 630 c is shown to have a first axis (e.g., axes 660 a, 660 b, and660 c) and a second axis perpendicular to the first axis (e.g., axes 665a, 665 b, 665 c). The facets 630 a, 630 b, and 630 c may be aligned,ordered, or oriented along the radial direction (e.g., along A-A′) and,therefore, are also aligned along their respective first axes. On theother hand, for each of the facets 630 a, 630 b, and 630 c, it may bepossible to introduce, assign, or control an angular change or offsetwith respect to their second axes. For example, for the facet 630 a, thesecond axis 665 a may be rotated or tilted by an angle δ₁, where0≤δ₁≤360°, or δ₁≤±90°, to a different position 670 a. Similarly for thefacet 630 b, where the second axis 665 b may be rotated or tilted by anangle δ₂, where 0≤δ₂≤360°, or δ₂≤±90°, to a different position 670 b,and for the facet 630 c, where the second axis 665 c may be rotated ortilted by an angle δ₃, where 0≤δ₃≤360°, or δ₃≤±90°, to a differentposition 670 c. The amount of tilt or rotation (e.g., δ₁, δ₂, and δ₃)for the second axis in each of the facets 630 a, 630 b, and 630 c can bechosen or assigned randomly (e.g., pseudo-randomly) such that there isno pattern or relationship in the amount of tilt or rotation in adjacentor consecutive facets, or among all of the facets in the reflectingstructure 615. The tilt or rotation of the second axes may result insome second axes rotating clockwise and some rotating counterclockwise.Moreover, while the amount of tilt or rotation of any one second axis israndomly assigned or selected, the overall distribution of therandomness may result in a uniform distribution across the entire set offacets in the reflecting structure 615.

Returning to FIG. 6A, with respect to the portion 620, a view along B-B′perpendicular to the radial direction 625 is illustrated in a diagram680 in FIG. 6D. In this example, five (5) facets 630 are shown forpurposes of illustration. The facets 630 as illustrated are showninclined backwards so that the top of the facets 630 appears furtheraway that the bottom.

As with FIG. 6B, each of the facets 630 in the diagram 680 is configuredor formed to have a specified angle relative to a plane or directionperpendicular to the surface of the reflecting structure 615 (not shown)which may be the same or different depending on the implementation ofthe reflecting structure 615.

A perspective view of some of the facets 630 in the diagram 680 is shownin a diagram 690 in FIG. 6E. In this view, each of the facets 630 d and630 e (which need not be adjacent to each other) is shown to have afirst axis (e.g., axes 660 d and 660 e) and a second axis perpendicularto the first axis (e.g., axes 665 d and 665 e). The facets 630 d and 630e may be positioned along an angular direction (e.g., along B-B′)perpendicular to the radial direction 625 where their first axes areordered or aligned in the radial direction 625. On the other hand, foreach of the facets 630 d and 630 e, it may be possible to introduce,assign, or control an angular change or offset with respect to theirsecond axes. For example, for the facet 630 d, the second axis 665 d maybe rotated or tilted by an angle δ₄, where 0≤δ₄≤360°, or δ₄≤±90°, to adifferent position 670 d. Similarly for the facet 630 e, where thesecond axis 665 e may be rotated or tilted by an angle δ₅, where0≤δ₅≤360°, or δ₅≤±90°, to a different position 670 e. The amount of tiltor rotation (e.g., δ₄ and δ₅) for each of the facets 630 d and 630 e canbe chosen or assigned randomly (e.g., pseudo-randomly) such that thereis no pattern or relationship in the amount of tilt or rotation inadjacent or consecutive facets.

As illustrated by FIGS. 6A-6E, one way to modify an otherwise “smooth”reflector to be able to produce the optical effects described in FIGS.4A-4C (e.g., flat ring optical effect) is to effectively “brush” thesurface of the reflector (e.g., the optically variable device 600) byintroducing a random or pseudo-random variation of the second axis ineach of the facets or mirrors that form the structured surface (e.g.,micro mirror array) of the reflector while maintaining alignment ororder in the first axis, thereby producing the single axis alignment ofmirrors described above.

FIG. 7 is a flow diagram that shows an example of a method 700 formaking an optically variable device or article such as the opticallyvariable device 600 in FIG. 6A.

At block 710, the method 700 may include providing a reflecting layer.In an example, the reflecting structure 615 may be a reflecting layer ormay be part of a reflecting layer.

At block 715 in block 710, the reflecting layer may be a top portion ofa first layer or disposed on a top surface of the first layer. In anexample, the reflecting structure 615 may be a reflecting layer and maybe disposed on a first layer, which may be the layer 645 or thesubstrate 610. In another example, the reflecting structure 615 and thelayer 645 may be made of a same material, in which case the reflectingstructure 615 may be a reflecting layer and a top portion of a firstlayer that combines the reflecting layer and the layer 645.

At block 720, the method 700 may include producing a reflectingstructure on the reflecting layer having multiple facets, the facetsbeing arranged in a spatial orientation that produces a flat ringoptical effect upon incidence of light. In an example, as shown in FIGS.6B and 6D, the reflecting structure 615 is produced by having multiplefacets 630 formed and arranged in a particular spatial orientation.

At block 725 in block 720, producing the reflecting structure on thereflecting layer may include applying a cast (see e.g., FIGS. 8A and 8B)for embossing the facets on a top surface of the reflecting layer.

In an aspect of the method 700, in the spatial orientation each facet isordered along a first axis and tilted at pseudo-random angles about asecond axis perpendicular to the first axis. As shown in the series ofFIGS. 6B-6E, the facets 630 a, 630 b, 630 c, 630 d, and 630 e arealigned or ordered along the first axes 660 a, 660 b, 660 c, 660 d, and660 e, and then randomly rotated or tilted about the second axes 665 a,665 b, 665 c, 665 d, and 665 e (e.g., rotated or tilted by pseudo-randomangles δ₁, δ₂, δ₃, δ₄, and δ₅). For each facet, the first axis maycorrespond to an axis along a longest dimension of the facet (e.g., thelength of the facet or mirror) and the second axis corresponds to anaxis along a shortest dimensions of the facet (e.g., the width of thefacet or mirror). In an example, the pseudo-random angles for each facetmay range from 0 to ±90°. Additionally, each facet is considered to beconfigured to produce a reflection from the incident light that is atleast partially diffuse for the first axis and at least partiallyspecular for the second axis.

In another aspect of the method 700, in the spatial orientation thefacets are ordered along radial lines from a center of the reflectingstructure. In an example, and as shown in FIGS. 6A-6E, the facets 630are spatially oriented such that the facets are aligned or ordered alongthe radial direction 625.

FIG. 8A shows a schematic diagram 800 having an example of an apparatus810 for making an optically variable device such as the opticallyvariable device 610 in FIG. 6. The apparatus 800 may include a pressingdevice 820 and a stamping device 830. The stamping device 830 may be ormay include a cast or stamp with a pattern that is generated by one ofseveral techniques, including lithography (e.g., e-beam lithography),scribing, and the like.

The stamping device 830 may be removably coupled to the pressing device820 and configured to transfer the pattern to a reflecting material(e.g., to a reflecting layer) upon the exertion of pressure by thepressing device 820, where the pattern includes a reflecting structure(e.g., the reflecting structure 615) having multiple facets arranged ina spatial orientation that produces a flat ring optical effect uponincidence of light on the patterned reflective material. The pressingdevice 820 may place the stamping device 830 on the surface of thereflecting material to produce the reflecting structure 615, which maybe disposed on the substrate 610 as described above. This process ofpressing a pattern to produce a desired reflecting structure 615 (e.g.,a desired micro mirror array with particular orientations for each ofthe facets or mirrors) may be also be referred to as foil stamping orfoil embossing. Once the pattern is transferred from the cast to thereflecting material resulting in a patterned reflective material (e.g.,the reflecting structure 615), the pressing device 820 may move thestamping device 830 away from the patterned reflective material.

FIG. 8B is a diagram 840 that illustrates an example of a stamp 835 ofthe stamping device 830 used to transfer a pattern as part of anembossing process described above in connection with FIG. 8A and theapparatus 810, and produce the reflecting structure 615 of the opticallyvariable device 600.

The optically variable device 600 made in accordance with the method 700and the apparatus 810 may include a first layer (e.g., the substrate 610and/or the layer 645), and a reflecting structure (e.g., the reflectingstructure 615) disposed on the first layer, where the reflectingstructure has a top surface including multiple embossed facets (e.g.,the facets 630 embossed using the cast 835), and where the facets arearranged in a spatial orientation (e.g., axis orientation) that producesa flat ring optical effect upon incidence of light (see e.g., flat ringoptical effects in FIGS. 4A-4C).

In an aspect of the optically variable device 600 made as describedabove, the in the spatial orientation each facet is ordered along afirst axis and tilted at pseudo-random angles about a second axisperpendicular to the first axis. For each facet, the first axiscorresponds to an axis along a longest dimension of the facet and thesecond axis corresponds to an axis along a shortest dimensions of thefacet. The pseudo-random angles for each facet may range from 0 to ±90°.

In another aspect of the optically variable device 600 made as describedabove, each facet is configured to produce a reflection from theincident light that is at least partially diffuse for the first axis andat least partially specular for the second axis.

In another aspect of the optically variable device 600 made as describedabove, in the spatial orientation the facets are ordered along radiallines from a center of the reflecting structure. In someimplementations, the facets are of the same size and/or the same shape.In other implementations, the facets vary in size and/or shape alongradial lines from a center of the reflecting structure.

In another aspect of the optically variable device 600 made as describedabove, the reflecting structure includes a reflecting material (e.g., ametallic material) or reflecting layer and is integrated with the firstlayer. In some implementations, the first layer is made of one of apolymeric material, a plastic material, or a metallic material.

In another aspect of the optically variable device 600 made as describedabove, a top surface of at least a subset of the facets is planar orsmooth.

In another aspect of the optically variable device 600 made as describedabove, a top surface of at least a subset of the facets includesmicrostructures.

FIG. 9 shows a flow diagram that illustrates an example of a method 900for making an optically variable device or article such as the opticallyvariable device 600 in FIG. 6A using the apparatus 810 in FIG. 8A.

At block 910, the method 900 includes providing a stamping device (e.g.,the stamping device 830) coupled to a pressing device (e.g., thepressing device 820) is provided.

At block 915 in the block 910, a cast (e.g., the cast 835) for embossinga pattern is provided as part of the stamping device.

At block 920, the method 900 includes pressing the stamping deviceagainst a top surface of a reflecting material to transfer the pattern.In an example, and as described above in connection with FIGS. 8A and8B, the stamping device 830 with the cast 835 is pressed against areflecting layer from which the reflecting structure 615 is formed byembossing the facets 630 using the pattern in the cast 835.

The concepts and techniques described in this disclosure address providea solution that enables yet another way to produce the unique opticaleffects described in this disclosure by controlling the direction,orientation, or rotation of each individual mirror or facet in a micromirror array to emulate or even surpass the optical effects that can beachieved using magnetically-oriented flakes.

It is understood that the specific order or hierarchy of blocks in themethods/flow charts disclosed is an illustration of exemplaryapproaches. Based upon design preferences, it is understood that thespecific order or hierarchy of blocks in the methods/flow charts can berearranged. Further, some blocks may be combined or omitted (e.g.,optional). The accompanying method claims present elements of thevarious blocks in a sample order, and are not meant to be limited to thespecific order or hierarchy presented.

Although the present disclosure has been provided in accordance with theimplementations shown, one of ordinary skill in the art will readilyrecognize that there could be variations to the embodiments and thosevariations would be within the scope of the present disclosure.Accordingly, many modifications may be made by one of ordinary skill inthe art without departing from the scope of the appended claims.

It should be appreciated to those of ordinary skill that various aspectsor features are presented in terms of systems that may include a numberof devices, components, modules, and the like. It is to be understoodand appreciated that the various systems may include additional devices,components, modules, etc., and/or may not include all of the devices,components, modules etc. discussed in connection with the figures.

What is claimed is:
 1. A device comprising: a reflecting structure, the reflecting structure comprising facets, the facets, in a spatial orientation, being configured to emulate an outside surface of a sphere, and the facets being aligned in a micro mirror array on an axis parallel to the outside surface of the sphere.
 2. The device of claim 1, further comprising: a substrate, wherein the reflecting structure is disposed on the substrate.
 3. The device of claim 1, where the facets are in a top surface of the reflecting structure.
 4. The device of claim 1, where the facets are embossed facets.
 5. The device of claim 1, where the facets are arranged in a spatial orientation that produces an effect upon incidence of light.
 6. The device of claim 5, where the effect is a flat ring optical effect.
 7. The device of claim 1, where the facets have a distributed or a random alignment perpendicular to radial lines associated with the outside surface of the sphere.
 8. The device of claim 1, further comprising: a substrate; and a layer that is between the reflecting structure and the substrate.
 9. A device comprising: a reflecting structure, the reflecting structure comprising facets, the facets, in a spatial orientation, being configured to emulate an outside surface of a sphere, and a reflection pattern from the facets emulating a brushed surface on the sphere.
 10. A method comprising: providing a reflecting layer; and producing a reflecting structure, on the reflecting layer, having facets, the facets, in a spatial orientation, being configured to emulate an outside surface of a sphere, and the facets being aligned in a micro mirror array on an axis parallel to the outside surface of the sphere.
 11. The method of claim 10, where the reflecting layer is disposed on a layer that is disposed on a substrate.
 12. The method of claim 10, where producing the reflecting structure comprises: applying a cast for embossing the facets on a top surface of the reflecting layer.
 13. The method of claim 10, where the facets are embossed facets.
 14. The method of claim 10, where the facets are arranged in a spatial orientation that produces an effect upon incidence of light.
 15. The method of claim 14, where the effect is a flat ring optical effect.
 16. The method of claim 10, wherein the facets have a distributed or a random alignment perpendicular to radial lines associated with the outside surface of the sphere.
 17. The method of claim 10, wherein a reflection pattern from the facets emulates a brushed surface on the sphere.
 18. A device comprising: a reflecting structure, the reflecting structure comprising facets, the facets, in a spatial orientation, being configured to emulate a surface of a sphere, and the faceting have a distributed or a random alignment perpendicular to radial lines associated with the surface of the sphere.
 19. The device of claim 18, where the facets are in a top surface of the reflecting structure.
 20. The device of claim 18, where the facets are embossed facets. 